Building construction



Sept. 25, 1962 c. F. MARONEY BUILDING CONSTRUCTION 5 Sheets-Sheei 1 Filed Sept. 11, 1958 W a Iago INVENTOR. CLAIQ F. MAQONEY M, m1

la mu AT TORJVEY Sept. 25, 1962 c. F. MARONEY BUILDING CONSTRUCTION 5 Sheets-Sheet 2 Filed Sept. 11, 1958 IN V EN TOR.

CLAIR MAQONEY BY 1/ QZQZ f M ATTORNEY Sept. 25, 1962 c. F. MARONEY BUILDING CONSTRUCTION 3 Sheets-Sheet 3 Filed Sept. 11, 1958 INVENTOR OLA/l2 1 MADONEY BY ATTORNEY United States Patent Ofiice 3,055,460 Patented Sept. 25, 1962 3,055,460 BUILDING CONSTRUCTION Clair F. Maroney, Sand Springs, Okla, assignor to Southwestern Porcelain Steel Corporation, Sand Springs, Okla, a corporation of Oklahoma Filed Sept. 11, 1958, Ser. No. 760,462 5 Claims. (Cl. 189-34) The present invention relates to material used in building construction. More particularly, the invention relates to a form for building material which can be readily assembled, as a unit, into the building structure and which has both strength and dimensional flexibility in erection.

Many items of buildings are now prefabricated. Prefabrication has the advantage of closely controlled factory conditions which will assure economy in erection and effective inspection. However, the designs of buildings of prefabricated units tends to become rigid because of standardization of prefabricated units. Obviously, some sacrifice of variation in form is required in order to mass-produce building units.

Fundamentally, the erection of load-bearing walls has generally required the provision of load-bearing frame members on a foundation. The frame members are designed to sustain roof loads, and anchor the completed wall to the foundation. The wall surface is provided by attaching various materials, in planar form, to the frame members to provide the wall surface in the vertical plane. There is a real problem in bringing material together efiiciently which will provide both strength and surface required.

Installation of interior walls with non-load-bearing units of standardized size offers still another problem. No room is easily planned for interior Walls. Erection of non-loadbearing wall panels must generally meet the fact that the total wall length required is smaller, or larger, than anticipated. Therefore, a flexible junction between wall panels, which is readily assembled, becomes highly desirable. One of the primary objects of the present invention is to combine the functions of load-bearing frame members with wall material of planar form into a unitary structure.

Another object of the invention is to provide a unitary construction panel having both the strength of a loadbearing frame member and the simplicity of a panel.

Another object of the invention is to provide a construction panel into which can be incorporated the required number of load-bearing frame members to bear roof weights and couple the wall to the foundation.

Another object of the invention is to provide distribution of vertical loads along the horizontal length of a load-bearing construction panel.

Another object of the invention is to provide a nonload-bearing construction panel which can be readily mounted on the load-bearing construction panel in a manner to provide finite horizontal adjustment of the overall length of the wall of panels.

Another object of the invention is to provide a nonload-bearing panel having a juncture with similar panels which provides elfective concealment of the attachment means to the load-bearing construction as well as a concealed caulking provision to seal between panels.

In one aspect, the present invention contemplates a simple load-bearing construction panel shaped to simultaneously provide the strength of a load-bearing frame member and the vertical surface of a wall. Incorporation of the strength of a load-bearing frame member in a construction panel results from extending the vertical edges of a sheet of panel material perpendicular to the plane of the main wall surface it provides and forming these edges, vertically, to have a cross-section which. is at least partially the cross-section of a conventional loadbearing frame member.

The present invention further contemplates a portion of the formed vertical edges of the panel being extended parallel to the plane of the main wall surface to provide a mounting surface for non-load-bearing interior construction panels. The invention further contemplates forming the top and bottom horizontal edges of the load-bearing construction panel to provide a surface upon which to mount, or to which to attach, continuous, formed, tie sections which will distribute the vertical loads on the panel construction on the one hand and anchor the panel construction to a foundation on the other.

The invention further contemplates the load-bearing construction panels being arranged in a combination in which they abut each other so as to form the complete cross-section of a conventional load-bearing frame memher in their junction. A desired number of load-bearing frame members may be incorporated into the recesses so provided to give additional strength to the combination for withstanding vertical loads.

Other objects, advantages and features of this invention will become apparent to one skilled in the art upon consideration of the written specification, appended claims, and attached drawings wherein- FIG. 1 is a perspective view of a corner of a building embodying features of the present invention;

PlG. 2 is an enlarged perspective view of a junction of two of the load-bearing wall panels of FIG. 1;

FIG. 3 is a perspective view of a single load-bearing wall panel embodying the present invention;

FIG. 4 is a perspective view of a section of a continuous formed section shown at the top and bottom of the FIG. 1 walls;

FIG. 5 is an elevation view of the end of the FIG. 3 panel with formed sections of FIG. 4 at its top and bottom;

FIGS. 6-8 are plan views of various forms available for the junction of FIG. 3 panels;

FIG. 9 is a perspective view of part of a building wall embodying features of the invention in which nonload-bearing panels form the interior wall surface;

FIG. 10 is a perspective view of a single non-loadbearing panel embodying the present invention;

FIG. 11 is a perspective View of a retainer bar member employed to bring the non-load-bearing panels of FIG. 9 together; and

FIG. 12 is a perspective view of junctions of both the load-bearing and non-load-bearing wall panels of FIG. 9.

FIG. 1 is established to show the arrangement of a load-bearing wall, embodying the present invention, mounted on a base. Base 1 is a concrete block, providing a level surface upon which the load-bearing walls are erected and to which they are anchored.

FIG. 1 shows one corner of the load-bearing walls of a complete building. The walls are comprised of panels 2, abutting each other, anchored to base 1 and arranged to receive a roof, not shown here. One of the panels 2 is broken away at one of its lower corners to illustrate how the wall is anchored to a continuous, formed, tie section 3 at its bottom. A continuous, formed, tie section 4 is shown along the top of the Wall to distribute the roof loads. A portion 5, of this top formed tie section 4, is shown somewhat exploded above its wall in order to indicate some of the structure with which these formed sections are joined to their walls.

The formed tie section 3 is simply nailed, riveted, or otherwise fixed to the edge of base 1. A bottom flange of each individual panel 2 is preferably attached by sheet metal screws to a flange of formed tie section 3 as indicated at 6. Pipe sections 7 are fixed to top and bottom formed sections so as to extend into the structure of the junction between adjacent panels 2. These pipe sections 7 are indicated on both bottom formed tie section 3 and the formed tie section 5. These pipe sections 7 are shown aligned with holes at the junctions between panels 2 to function as a stable anchor between the formed sections and the load-bearing walls of panels 2. The pipe sections 7 are positively pinned to the panels by through-bolts.

In FIG. 2 the structure within the junction between the vertical edges of each of panels 2 is shown in detail. The vertical end portions of the panels 2 are given a particular form. The formation provides surfaces 8 which lie flat against similar surfaces of other panels. Through matching surfaces 8, a series of holes are provided. Fasteners, such as bolts 9 shown, are inserted through these holes to bring the surfaces together and maintain union between the adjacent panels 2.

FIGS. 2 and 3 must be taken together to fully appreciate how each panel 2 is formed, in detail, and the advantages gained when a series of the panels 2 are joined together into a load-bearing wall as illustrated in FIG. 1.

FIG. 3 shows to the best advantage how a single panel 2 has vertical end portions extending generally normal to the surface plane of the main portion. These vertical end portions are formed, vertically, into the shape of a partial cross-section of a load-bearing frame member. The circular shape of a load-bearing frame member, so constructively formed, is indicated at 15. When panels 2 are brought together by bolt-fasteners 9, a complete cross-sectional shape of a load-bearing frame member is formed by the matching shapes 15. The equivalent of a load-bearing frame member formed in this manner, at each junction of panels 2, has been found to have a surprising degree of strength. A new and novel result has been obtained by so incorporating into the load-bearing wall of panels 2 the equivalent of a load-bearing frame member.

Shapes are not restricted to being cylindrical. Further, their hollow cavity may be given further strength by inserting a pipe, or post, which can be anchored top and bottom, between base 1 and roof. Also, cavity 15 can be filled with concrete, or similar material, which will harden into a solid load-bearing structural member within the junction cavity of panel 2. The various specific forms, based on the disclosure of FIGS. 2 and 3, should be obvious to those skilled in the art.

Further details of panel 2 construction are illustrated by flange 10 which provides mounting surfaces for a nonload-bearing wall panel. Flange 10 is an additional form given to the vertical end portions of panels 2 as they extend normal to the plane of the main surface of the panel. In these flanges 10 are provided holes 11 used to accommodate fasteners for the non-load-bearing wall panels.

The horizontal upper and lower edges of the panels 2 are also formed into flanges 12. Flanges 12 extend normal to the plane of the main surface of panels 2. These flanges 12 become horizontal surfaces which specifically attach to the continuous formed tie sections 3 and 4. Holes 13 are provided in the flanges 12 to accommodate fasteners 6 as illustrated in FIG. 1.

FIG. 4 illustrates a portion of the formed tie section to which the flanges 12 attach by fasteners 6. FIG. 4 reveals the cross-section of the formed tie section as substantially C-shaped. The back of the C-shape is flat in providing a surface which may be placed against the horizontal surface of base 1 or to support and distribute roof loads evenly. The up-turned edges of the C-shape, at 17, form a track in which the pipe section 7 is mounted. Pipe section 7 is shown with a foot member 18 captured between the flanges 1'7.

Foot member 18 is given a generally diamond shape. This shape enables the member to be placed between flanges 17 and turned into locking engagement and capture beneath flanges 17. Pipe section 7 is welded to foot member 18 to extend vertically.

Flanges 17 have holes 19 formed in them to match with holes 13 in flanges 12. Bolt fasteners, or sheet metal screws, 6 are then readily inserted through these holes to bring the formed section into union with the panels. The complete assembly is attached to base 1 by rivets, nails, or similar fasteners driven through flat surface 16' by one of the several machines available.

FIG. 5 is established to show the combination of for-med tie sections, panel 2 and base 1 as brought together by fasteners. This section, taken through a junction of panels 2, shows how formed tie section 3 is attached to base 1 by fastener member 20, driven directly into concrete base 1. The cavity formed by shapes 15 is shown as incorporating pipe sections 7 extending vertically therein from the formed tie section. Pipe sections 7 and panel structure are pinned together by through-bolts.

FIG. 5 additionally shows the ease with which a flashing structure may be inserted between lower formed tie section 3 and flange 12. Flashing structure 21 is shown as a simple strip of material captured between flange 17 and flange 12 by bolt-fastener 6. Flashing strip 21, formed downwardly, lies flush against base 1 and provides an external surface to cover formed section 3 and base 1 to any extent desired.

FIGS. 6-8 are established to show the variations for cross-sectional shapes which may be provided at 15 in the junctions of panels 2. FIG. 6 shows circular shape of the preceding illustrations and, additionally, shows pipe 22 incorporated for such additional load-bearing strength as required.

FIGS. 7 and 8 show shapes 23 and 24 as square in cross-section. Additionally, post members 25 and 26 are shown within these shapes as representative of strengthening structure as may be required.

The material of the panels 2 may be any of a number of available kinds having the desired strength, finish, etc. The actual reduction to practice of the invention employed porcelainized steel. However, the inherent nature of the invention would lend itself to some form of extruded plastic. Obviously a wide variety of materials lend themselves to embodying the invention.

FIGS. 9-12 are used to illustrate the invention em- 'bodied in a non-load-bearing wall construction. This non-load-bearing wall is shown attached to the interior of the load-bearing walls of FIG. 1. When the combination is completed, a building is produced which is readily and simply erected with a minimum of time, labor, and size variation of material. It is to be clearly understood, however, that the non-load-beariug wall disclosed could be as readily attached, and combined with, loadbearing walls other than those of FIG. 1. The requirements for a base to which the non-load-bearing wall may be attached, are simple. They can be supplied by a wide variety of existing forms of load-bearing walls.

FIG. 9 illustrates two corners of a building having the exterior, load-bearing walls of FIG. 1. The load-bearing walls of panels 2 have the non-load-bearing walls attached to flanges 10 at the junctions of panels 2. The assembly is brought together with ease and rapidity because of the forms developed for the parts of the non-load-bearing wall under the concepts of the present invention. Broadly, the essential elements provided are a retaining bar member which is attached to the flanges 10 for holding matching edges of the non-load-bearing panels, and the panels themselves.

Panels 30 are shown assembled, in FIG. 9, to retaining bars 31. The mid-sections of the panels are formed at right angles about the corners shown. The horizontal dimensions of the panels vary in extending through the corners. However, the form given each horizontal edge of the panels 30 consistently embodies the invention. The new result obtained by these forms of panel edges is a high degree of flexibility for the horizontal dimension of the completed non-load-bearing wall. The coupling between panel edges and retainer bar can be varied to a large degree without breaking down the junction. Further, the ease of assembly gives a remarkable advance in building construction.

FIG. 10 shows the non-load-bearing panel 30 in detail. The vertical edge 32. is simply a raw, straight, edge. The opposite vertical edge has a bead form 33 which is broadly defined as having the shape of a channel with a return flange. The back portion 34 and side portions 35 and 36 define the channel shape clearly. The return flange portion 37 completes the shape of this bead which embodies the invention. The coupling of a raw edge of one panel 30 with a bead form 33 by a retainer bar 31 is easily accomplished with a minimum of tools and hand operations. The result of coupling a series of panels 30 together is the formation of the non-load-bearing wall illustrated in FIG. 9.

FIG. 11 shows bar 31 in the form of a simple, elongated strip with a return flange portion 38. The bar 31 is described as having a J-shape with a flange leg 39 longer than a clipping flange leg 38. Holes =40 are formed along the edge of flange leg 39 so attaching bolts, or sheet metal screws, may be passed through them and holes 11 of flange 10 on the load-bearing-panels 2. When bar 31 is mounted on the inside of the load-bearing wall, it readily couples a raw edge 32 and bead 34 into a junction for the interior non-load-bearing wall which is neat in appearance, quickly made with a minimum of labor, flexible in horizontal dimension and easily sealed against moisture.

' FIG. 12 shows all of the elements of the combination of the external load-bearing wall and the interior nonload-bearing wall brought together in a union in which each wall carries out its separate function. Retainer bar 31 is shown positioned on, and attached to, flange 10. Bead 33 is slipped over bar 31 so its return flange 37 hooks flange 38 of track 31. Further, in extending back to hook flange 38, flange 37 is arranged parallel the plane of the main portion of panel 30. Also, flange 37 is spaced forward a distance equal the thickness of the panel material. Therefore, as the FIG. =12 assembly is brought together, flange 37 is contiguous the adjacent panel with its raw edge placed within the bead 33, the main portions of the adjacent panels being in the same plane. This arrangement accommodates the flange 38 loosely in the interior of the channel of bead 33. Raw edge 32 of another panel 349 is then slipped between flange 39 and return-flange '37. Because of the horizontal depth of bead 33 the raw edge has a finite horizontal distance it can travel while remaining coupled to the bar 31 and returnflange 37. This arrangement has comparatively great flexibility, compared with other building constructions. This embodiment of the invention permits a comparatively wide variation of the interior dimensions of a room provided with this non-load-bearing wall structure. As indicated heretofore, it is very difiicult to anticipate the interior dimensions of a room. The present invention permits a large latitude in this planning prior to actual installation of the interior walls.

An additional advantage of the arrangement of FIG. 12 is found in use of the unfilled cavity 41 of the bead 33. Various caulking compounds can be placed in this cavity 41 before the FIG. 12 assembly is completed. As the raw edge 32 and return-flange 37 are engaged over clip-flange 38, the excess of the caulking compound in cavity 41 will be forced out. This excess of compound can be wiped from the joint, leaving a junction sealed to the limits of the efliciency of the caulking compound.

It is to be further understood that bar 31 is not limited to the single, elongated form disclosed. A series of similar sections can be used, if desired, making a series of clips which may be quite satisfactory if the material of the panels 30 is sufficiently stiif to not bulge or gap at the junction, or seam.

From the foregoing it will be seen that this invention is one well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and which are inherent to the apparatus.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawing is to be interpreted as illustrative and not in a limiting sense.

The invention having been described, what is claimed 1s:

1. A non-load-bearing wall panel comprising,

a main portion arranged in a single plane so as to provide a surface to function as a wall, a raw edge on one end of the main portion, and a single bead formation on the panel which is developed on the end of the main portion opposite the raw edge by turning the edge opposite the raw edge under and into parallel alignment and a distance above the plane of the main portion equal the thickness of the main portion so as to be arranged contiguous the main portion of a similar panel arranged in the plane of the main portion with its raw edge received in the bead. 2. A load-bearing wall consisting of; a series of load-bearing panels with each panel having, a .main portion arranged in a single plane so as to provide a surface to function as a portion of the wall,

vertical end portions extended generally normal to the plane of the surface of the main portion and shaped to provide the complete half of the form of a vertically extended three-dimensional frame member, the frame member being completed in form between and with the abutting vertical end portions of others of the series of panels, fastening means in the vertical end portions, whereby the abutting vertical end portion of a second and similar load-bearing wall panel of the series may be joined to one of the first vertical end portions in forming the complete half of the form of the vertically extended three-dimensional frame member between and with the abutting vertical end portions,

and mounting surfaces on the horizontal upper and lower edge of each panel;

tie sections in the form of a cross section of a channel with return flanges, one flange of which is fastened to a mounting surface of the upper and lower edges of the panel;

and anchor structures captured by the return flanges of the tie sections and protruding vertically into the end of the forms of the frame member between the abutting vertical end portions and attached to the panel.

3. A wall consisting of; a series of load-bearing panels with each panel having, a main portion arranged in a single plane so as to provide a surface to function as a portion of the wall, vertical end portions extended generally normal to the plane of the surface of the main portion and shaped to provide the complete half of the form of a vertically extended three-dimensional frame member, the frame member being completed in form between and with the abutting vertical end portions of others of the series of panels,

fastening means in the vertical end portions, whereby the abutting vertical end portion of a second and similar load-bearing wall panel of the series may be joined to one of the first vertical end portions in forming the complete half of the form of the vertically extended three-dimensional frame member between and with the abutting vertical end portions,

and mounting surfaces on the horizontal upper and lower edge of each panel;

tie sections in the form of a cross-section of a channel with return flanges, one flange of which is fastened to a mounting surface of the upper and lower edges of the panel;

anchor structures captured by the return flanges of the tie sections and protruding vertically into the end of the forms of the frame member between the abutting vertical end portions and attached to the panel; a retaining bar having a J-shaped cross-section mounted by the extended side on the load-bearing panels; and two non-load-bearing wall panels, each having; a main portion arranged in a single plane parallel to the load-bearing wall in providing a surface to function as a portion of the interior wall,

a raw edge on one edge of the main portion,

and a single bead formation on the panel which is developed on the end of the main portion opposite the raw edge by turning the edge opposite the raw edge under and into parallel alignment and a distance above the plane of the main portion equal the thickness of the main portion so as to be arranged contiguous the main portion of the other panel arranged in the plane of the main portion with its raw edge received in the head,

the two non-load-bearing wall panels held within the J-shape of the retaining bar by the raw edge of one and the beaded edge of the other.

4. A wall consisting of;

a series of load-bearing panels with each panel hava main portion arranged in a single plane so as to provide a surface to function as a portion of the wall,

vertical end portions extended generally normal to the plane of the surface of the main portion and shaped to provide the complete half of the form of a vertically extended three-dimensional frame member, the frame member being completed in form between and with the abutting vertical end portions of others of the series of panels,

fastening means in the vertical end portions, whereby the abutting vertical end portion of a second and similar load-bearing wall panel of the series may be joined to one of the first vertical end portions in forming the complete half of the form of the vertically extended three-dimensional frame member between and with the abutting vertical end portions,

and mounting surfaces on the horizontal upper and lower edge of each panel;

tie sections in the form of a cross-section of a channel with return flanges, one flange of which is fastened to a mounting surface of the upper and lower edges of the panel;

anchor structures captured by the return flanges of the tie sections and protruding vertically into the end of the forms of the frame member between the abutting vertical end portions and attached to the panel;

and two non-load-bearing wall panels, each having;

a main portion arranged in a single plane parallel to the load-bearing wall in providing a surface to function as a portion of the interior wall,

a raw edge on one edge of the main portion,

a single bead formation on the panel which is developed on the end of the main portion opposite the raw edge by turning the edge opposite the raw edge under and into parallel alignment and a distance above the plane of the main portion equal the thickness of the main portion so as to be arranged contiguous the main portion of the other panel arranged in the plane of the main portion with its raw edge received in the bead;

and a retaining bar having a J-shaped cross-section mounted by the extended side on the load-bearing panels with its shorter side extended in the direction opposite to the direction in which the turned under portion of the beaded edge extends, the two nonload-bearing wall panels held within the J-shape of the retaining bar by the raw edge of one and the beaded edge of the other to provide a finite range of horizontal adjustment of the raw edge within the head without uncoupling the raw edge from engagement with the bead and retaining bar and without distortion of the visual continuity of the assembly.

5. A wall consisting of;

a series of load-bearing panels with each panel having,

a main portion arranged in a single plane so as to provide a surface to function as a portion of the wall,

vertical end portions extended generally normal to the plane of the surface of the main portion and shaped to provide the complete half of the form of a vertically extended three-dimensional frame member, the frame member being completed in form between and with the abutting vertical end portions of others of the series of panels,

fastening means in the vertical end portions, whereby the abutting vertical end portion of a second and similar load-bearing wall panel of the series may be joined to one of the first vertical end portions in forming the complete half of the form of the vertically extended three-dimensional frame member between and with the abutting vertical end portions,

and mounting surfaces on the horizontal upper and lower edge of each panel;

tie sections in the form of a cross-section of a channel with return flanges, one flange of which is fastened to a mounting surface of the upper and lower edges of the panel;

anchor structures captured by the return flanges of the tie sections and protuding vertically into the end of the forms of the frame member between the abutting vertical end portions and attached to the panel;

and two non-load-bearing wall panels, each having;

a main portion arranged in a single plane parallel to the load-bearing wall in providing a surface to function as a portion of the interior wall,

a raw edge on one edge of the main portion,

a single bead formation on the panel which is developed on the end of the main portion opposite the raw edge by turning the edge opposite the raw edge under and into parallel alignment and a distance above the plane of the main portion equal the thickness of the main portion so as to be arranged contiguous the main portion of the other panel arranged in the 9 plane of the main portion with its raw edge received in the bead;

a retaining bar having a J-shaped cross-section mounted by the extended side on the load-bearing panels with its shorter side extended in the direction opposite to the direction in which the turned under portion of the beaded edge extends, the two non-load-bearing Wall panels held within the J-shape of the retaining bar by the raw edge of one and the beaded edge of the other to provide a finite range of horizontal adjustment of the raw edge within the bead without uncoupling the raw edge from engagement with the bead and retaining bar and without distortion of the visual continuity of the assembly, and caulking compound within the bead and about the turned under portion and raw edge within the bead.

References Cited in the file of this patent UNITED STATES PATENTS 

